Electronic device housing and method for manufacturing the same

ABSTRACT

A housing is provided, with a plurality of tridimensional patterns formed on opposite surfaces of the housing. The patterns are formed by stamping process.

1. TECHNICAL FIELD

The disclosure relates to electronic device housings and methods for manufacturing the housings and, particularly, to a housing forming tridimensional patterns thereon and a method of manufacturing the housing.

2. DESCRIPTION OF RELATED ART

Nowadays, portable electronic devices, such as mobile phones, laptops, or personal digital assistants, are widely used. Metallic housings are often used to protect and decorate these portable electronic devices. Generally, in a typical manufacturing process, the housings are spray-painted for decoration and protection. However, the paint tends to have a low wear-resistance, which will be unattractive over time.

BRIEF DESCRIPTION OF THE DRAWINGS

Many aspects of the present embodiments can be better understood with reference to the following drawings. The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of the present embodiments. Moreover, in the drawings, all the views are schematic, and like reference numerals designate corresponding parts throughout the several views.

FIG. 1 is a schematic view of an embodiment of an electronic device housing.

FIG. 2 is a cross-sectional view of the housing of FIG. 1, taken along line II-II.

FIG. 3 is an enlarged view of a circled portion III of FIG. 1.

FIG. 4 is an enlarged view of part of the cross-sectional view of FIG. 2.

FIG. 5 is a flowchart of a method, in accordance with an embodiment, for manufacturing the housing shown in FIG. 1.

DETAILED DESCRIPTION

The disclosure is illustrated by way of example and not by way of limitation in the figures of the accompanying drawings in which like references indicate similar elements. It should be noted that references to “an” or “one” embodiment in this disclosure are not necessarily to the same embodiment, and such references mean at least one.

Referring to FIG. 1, an exemplary embodiment of an housing 100 may be used for portable electronic devices, such as mobile phones, laptops, or notebook computers.

Referring to FIGS. 2 and 3, the housing 100 is approximately rectangular and includes an outer surface 101 and an inner surface 102 opposite to the outer surface 101. A plurality of tridimensional patterns 110 is formed on the outer surface 101 and the inner surface 102. The patterns 110 are formed by a stamping process with a stamping die (not shown). The patterns 110 of the inner surface 102 are opposite to the patterns 110 of the outer surface 101, in other words, if some patterns 110 of the outer surface 101 are intaglio, the corresponding patterns 110 of the inner surface 102 are relief, and vice versa. A flange 12 extends towards the inner surface 102 side from four edges of the housing 100. An arc-shaped corner is formed between every two adjacent sides of the flange 12. A cutout 14 is defined in a middle of a side of the housing 100. The flange 12 is formed by stamping the edges of the housing 100.

Referring to FIG. 4, the housing 100 can be made of metal, such as copper, iron, aluminum, titanium, or alloys including one or more of the metals. In one embodiment, aluminum alloy sheet metal is used. The thickness T of the sheet metal ranges from about 0.2 millimeters (mm) to about 1.5 mm. In one embodiment, the thickness is about 0.8 mm.

Referring to FIG. 5, a first exemplary embodiment of a method for manufacturing the housing 100 is provided. The method includes the following steps.

Step 902, sheet metal is provided and embossed by stamping the sheet metal with a stamping die. The blanking clearance of the stamping die can range from 0 to 10% T, and also can be negative clearance blanking, in one embodiment, the blanking clearance is zero.

A male die of the stamping die forms a plurality of relief patterns, while a female die of the stamping die forms a plurality of intaglio patterns corresponding to the relief patterns of the male die. The sheet metal is transported between the male die and the female die and sandwiched between the male die and the female die to form the patterns 110.

Referring to FIG. 4, the depth t of the intaglio patterns 110 can range from about 0.02 mm to 20% T. In one embodiment, the depth t is about 0.03 mm. After the sheet metal is embossed to form the housing 100, the total thickness of the housing 100 is T+t. The total length of the edges of the patterns 110 per square meter is about 650 meters (m) but can vary according to the stamping die used.

The curvature radius r1 of the edges of the patterns 110 is at least 0.05 mm everywhere. The curvature radius r2 of an angle α between a sidewall and a bottom wall of the patterns 110 may be at least 0.005 mm, and in this embodiment, ranges from 0.005 mm to 0.01 mm. The angle α between the sidewall and the bottom wall of the patterns 110 can be in a range of about from 90 to 110 degrees, and in this embodiment, is 90 degrees.

Step 904, the sheet metal embossed is cut to form an essentially rectangular shape and then sides of the metal board are finished.

Step 906, the finished sheet metal is stamped to elongate to form the flange 12. Referring to FIG. 2, the height H of the flange 12 is less than 20 mm. A radius R of the arc-shaped corner formed between every two adjacent sides of the flange 12 may be R≧⅕ H or R≧3 T.

Step 908, the finished sheet metal with flange 12 is side cut to form the housing 100.

Step 910, the housing 100 is anodized to form an anodic film on the inner surface 102 and the outer surface 101. The housing 100 is then placed into a dyeing container (not shown) containing dye (e.g., pigment/paint), and the dye is absorbed into the holes of the oxide film. In this way, the housing 100 is dyed a predetermined color. Finally, the dyed housing 100 is placed into a container (not shown) of resin particulates (for example, fluorine resin, epoxy resin or polyvinyl resin) suspended in liquid (for example, water or ethanol). The resin particulates form a hard protective film (not shown) on the oxide film, giving the housing 100 great wear-resistance and a high degree of polish/shine.

Understandably, the shape of the housing 100 can be adjusted.

It is believed that the present embodiments and their advantages will be understood from the foregoing description, and it will be apparent that various changes may be made thereto without departing from the spirit and scope of the description or sacrificing all of its material advantages, the examples hereinbefore described merely being exemplary embodiments. 

1. A housing comprising: an outer surface; and an inner surface; wherein a plurality of tridimensional patterns is formed on the outer surface and the inner surface by a stamping process, the patterns of the inner surface is opposite to the patterns of the outer surface.
 2. The housing of claim 1, wherein the housing is made of copper, iron, aluminum, titanium, singly or in combination.
 3. The housing of claim 1, wherein the housing is made of aluminum alloy.
 4. The housing of claim 1, wherein the housing is anodized.
 5. The housing of claim 1, wherein the patterns on the inner surface is intaglio and the patterns on the outer surface is relief.
 6. The housing of claim 1, wherein the patterns on the inner surface is relief and the patterns on the outer surface is intaglio.
 7. The housing of claim 1, wherein a height or depth of the patterns is about 0.03 millimeters.
 8. The housing of claim 1, wherein the thickness of the housing is about 0.8 millimeters.
 9. The housing of claim 1, wherein a flange extends towards the inner surface from edges of the housing by stamping the housing.
 10. The housing of claim 10, wherein an arc-shaped corner is formed between every two adjacent sides of the flange.
 11. The housing of claim 11, wherein a cutout is defined in a middle of a side of the housing.
 12. The housing of claim 1, wherein in length of the patterns per square meter is 650 meters.
 13. A method for manufacturing a housing, the method comprising: providing sheet metal; and embossing the sheet metal by stamping process to form a plurality of tridimensional patterns on two opposite surfaces of the sheet metal, the patterns of the two opposite surfaces are opposite to each other.
 14. The method of claim 13, further comprising the step of anodizing the housing after forming the patterns.
 15. The method of claim 13, wherein the blanking clearance of the stamping die is zero blanking clearance.
 16. The method of claim 13, wherein the blanking clearance of the stamping die ranges from 0 to 10% of T, where T is a thickness of the sheet metal.
 17. The method of claim 13, wherein a thickness of the sheet metal ranges from 0.2 millimeters (mm) to 1.5 mm. 